Exercise 2-1

Continuous Process Control

EXERCISE OBJECTIVE Control a continuous pH process.

DISCUSSION OUTLINE The Discussion of this exercise covers the following points:

ƒ Continuous processes

ƒ
Continuous process example: water treatment system.
Quarter-amplitude decay ratio

DISCUSSION Continuous processes

A continuous process is a process in which the input and output flows are
continuous. Continuous operations last for weeks to months and are used to treat
very large volumes. When fluids are involved, large quantities of reactants are
treated continuously over a long period of time. Thus, efficiency is greatly
improved and the labor cost is reduced. Figure 2-8 shows a simplified continuous
flow reactor for a pH process.

Ideal mixing device

‫ܨ‬ሾଷ ା ሿ଴

‫ܨ‬ሾଷ ା ሿ

Figure 2-8. Simplified continuous flow reactor for a pH process.

As shown in Figure 2-8, the input and output flows (F) are equal, allowing the
volume in the tank reactor to remain constant over time. Only the concentrations
of the chemical species in solution change over time.

When reagents with good solubility are used, chemical reactions involved in pH
processes can be approximated as instantaneous reactions. However, when a
reagent has poor solubility, chemical reactions take more time and chemical
equilibrium is not reached at steady-state. For example, calcium hydroxide,
ƒሺሻଶ , also known as hydrated lime, is widely used as a base reagent in
industrial applications because of its low cost. Calcium hydroxide has a low
solubility, therefore when it is in the presence of an acid, only small quantities of

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Ex. 2-1 – Continuous Process Control  Discussion

dissociated molecules can form hydroxide ions and neutralize the acid. Slowly,
as the hydroxide ions are consumed, more calcium hydroxide molecules
dissolve, and the cycle repeats. In this example, the neutralization is slow
because only a small quantity of reagent participates in the reaction.

The following points summarize the main characteristics of the idealized

continuous flow pH process shown in Figure 2-8:

x The reactant is treated continuously.

x The flow in and out of the tank is equal.

x The volume is constant over time.

x The continuous flow pH process is used to treat very large volumes.

x The input flow has a hydronium concentration ሾଷ ା ሿ଴ .

x The output flow has a hydronium concentration ሾଷ ା ሿ.

x The continuous flow pH process is a high-efficiency process.

Continuous process example: water treatment system

Raw water from a river, a lake, or a well must be treated before it can be sent
into the public water distribution system. Treating water is essential to human
health issues as well as for industrial quality control issues. Raw water contains
sulfates, iron, chlorides, dissolved solids, and has a pH and hardness that can
vary. To make it safe for consumption and for industrial uses, water must
undergo a series of filtration and chemical treatments. Since clean water must be
continuously provided to the public water distribution system, the water treatment
plants continuously run their processes. Figure 2-9 illustrates a public water
treatment system typical for a small town.

First, raw water enters the system through either a head tank for surface water
or, if groundwater is the source, through a head tank equipped with an aerator.
The aerator helps remove dissolved gases and oxidize iron. Next, the water is
sent to a unit called the solids contact clarifier. In this tank, the water pH is raised
allowing substances such as iron and manganese to precipitate, reducing
turbidity. A helical flow created in the contact clarifier unit directs slurry to the
inner cone (slurry concentrator). Clarified water rises to the top of the cone where
chlorine is added to kill bacteria. The water then enters a helical flow
recarbonation tank. In this tank, the pH is lowered to drinking water's normal
range and fluoride is added. The water is filtered through an activated carbon
and sand filter and finally directed into a large reservoir, where chlorine is added
again. Each of these tasks, including pH control, must be controlled and carefully
monitored using advanced process control techniques.

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Ex. 2-1 – Continuous Process Control  Discussion

Helical flow
Head tank / aerator Solids contact clarifier recarbonation
tanks

Well
water

Slurry
discharge Slurry
Head tank concentrator

Rain
water
Wet well and
pump station

Activated carbon
and sand filter

Reservoir

Figure 2-9. Typical public water treatment system.

Quarter-amplitude decay ratio

John G. Ziegler and Nathaniel B. Nichols, pioneers in control engineering,

established a criterion to determine if a controller is appropriately tuned. This
criterion is the quarter-amplitude decay ratio. It states that, for two successive
oscillations, the amplitude of the second oscillation should be one fourth of the
amplitude of the first oscillation.

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Ex. 2-1 – Continuous Process Control  Procedure Outline

Controlled
variable

‫ܣ‬ଵ
‫ܣ‬ଵ ‫ܣ‬ଶ
‫ܣ‬ଶ ൌ ‫ܣ‬ଷ ൌ
Ͷ Ͷ

Time

Set point

Figure 2-10.Quarter-amplitude decay ratio.

The presence of a quarter-amplitude decay ratio in a response is a rough

approximation for the optimal tuning of PID controllers. A controller is generally
considered to be reasonably tuned when it satisfies this criterion; but fine-tuning
may be required to adapt the controller response to a specific process control
application.

The quarter-amplitude decay response is a compromise between an

underdamped and an overdamped response. The process response is
overdamped when the controlled variable slowly returns to the set point after the
step change without overshooting it. The response is underdamped when the
controlled variable quickly returns to the set point with one or more overshoots
before stabilizing. An underdamped response often means that the controller
reacts too aggressively to correct the error, thereby overdoing it.

PROCEDURE OUTLINE The Procedure is divided into the following sections:

ƒ Set up and connections

ƒ Filling the upper tank
ƒ Tuning the controller for continuous pH process control
ƒ Controlling a continuous pH process
ƒ Neutralizing the process water
ƒ Curve analysis

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Ex. 2-1 – Continuous Process Control  Procedure

PROCEDURE Set up and connections

Before using ANY of the chemicals provided with the pH Process Control
Training System. Read the chemical MSDS and wear the appropriate personal
protective equipment.

1. Use the piping and instrumentation diagram (P&ID) shown in Figure 2-11 to
connect the equipment. If your training system is a Series 3532, use
Figure 2-12 and Figure 2-13 to position the equipment correctly on the
training system frame. If your training system is a Series 3531, use
Figure 2-14 and Figure 2-15 to position the equipment correctly on the
training system frame. Use the basic setup presented in the Familiarization
with the Training System manual. Table 2-2 lists the equipment you must add
to the basic setup in order to set up your system for this exercise.

Table 2-2. Equipment required for this exercise.

Name Part number Identification

Controller * AIC
Volumetric flask 38406
Scopulla 38442
Phosphoric acid solution 1.0 N 38481
Phenol red 38446
Graduated cylinder 38447
Latex gloves 40331-54
Pipette 40331-65
Safety glasses 40348
pH transmitter 46945 AIT
Metering pumps 46956
Paperless recorder 46972 UR
Chemical tank 46994

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Ex. 2-1 – Continuous Process Control  Procedure

Pump 2 (fresh
water pump) Upper tank

Pump 1
(acid pump)

Pump 3
(Draining)

Acid (ଷ ସ solution

0.04 mol/L)

Main tank

Figure 2-11. P&ID.

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Ex. 2-1 – Continuous Process Control  Procedure

Figure 2-12. Setup (front view, series 3532).

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Ex. 2-1 – Continuous Process Control  Procedure

Figure 2-13. Setup (side view, series 3532).

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Ex. 2-1 – Continuous Process Control  Procedure

Figure 2-14. Setup (front view, series 3531).

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Ex. 2-1 – Continuous Process Control  Procedure

Figure 2-15. Setup (side view, series 3531).

2. Wire the emergency push-button so that you can cut power in case of an
emergency. The Familiarization with the Training System manual covers the

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Ex. 2-1 – Continuous Process Control  Procedure

security issues related to the use of electricity with the system as well as the
wiring of the emergency push-button.

3. Do not power up the instrumentation workstation yet. Do not turn the

electrical panel on before your instructor has validated your setup—that is
not before step 9.

4. Connect the pH transmitter to the controller input and the metering pump
delivering acid to the controller output. Be sure to include the recorder in your
connections. On channel 1 of the recorder, plot the output signal from the
controller and on channel 2, plot the signal from the transmitter. Be sure to
use the analog input of your controller to connect the pH transmitter.

Phosphoric acid is corrosive and harmful if swallowed. Do not breathe the vapor.
Avoid eye and skin contact. Avoid prolonged or repeated exposure. When
handling, wear chemical-resistant gloves, chemical safety goggles, and a lab
coat. Refer to the MSDS for more details on this product.

5. For this continuous pH process, the chemical tank must be filled with a
solution of 0.04 mol/L of phosphoric acid. This is half the concentration of the
solutions used in the previous exercises. Consult the Measurement manual
for a detailed procedure to prepare this solution.

6. With this setup, the addition of fresh water coming from the water tank dilutes
the process water and, therefore, changes its pH. Make sure the upper tank
is properly installed at the top of the process workstation. Do not fill the upper
tank with water yet. Consult the Familiarization with the Training manual for a
detailed on how to install the upper tank.

7. Before proceeding further, complete the following checklist to make sure you
have set up the system properly. The points on this checklist are crucial
elements for the proper completion of this exercise. This checklist is not
exhaustive. Be sure to follow the instructions in the Familiarization with the
Training System manual as well.

f
All unused male adapters on the column are capped and the flange is
properly tightened.

x The hand valves are in the positions shown in the P&ID.

x The chemical tank is filled with the appropriate solution and is carefully
labeled.

x You are wearing the appropriate PPE.

x The vent tube is properly installed.

x The paperless recorder is set up and configured to record the output of the

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Ex. 2-1 – Continuous Process Control  Procedure

pH transmitter and the controller output.

x The three metering pumps are properly connected. The first metering pump
injects acid solution in the process water. The second metering pump is
connected to the upper tank and supplies fresh water into the column.
Finally, the third metering pump drains water from the column and returns it
to the main tank of the process workstation.

x The upper tank is properly secured at the top of the process workstation
and the drain coupling of the upper tank is connected to HV4 on the
process workstation (without this connection, it is difficult to empty the
upper tank without spilling water).

8. Ask your instructor to check and approve your setup.

Filling the upper tank

9. Power up the electrical unit, this starts all electrical devices.

10. Make sure the pH probe is properly inserted into the connection port on the
process workstation.

11. Test your system for leaks. Use the drive to make the pump run at low speed
in order to produce a small flow rate. Gradually increase the flow rate, up
to 50% of the maximum flow rate that the pumping unit can deliver (i.e., set
the drive speed to 30 Hz). Repair all leaks.

12. Start the pump and set the drive speed to 30 Hz.

This setup uses a telescopic pipe which can extend if the pump runs at a too high speed.
Be sure to set the drive speed to a maximum of 30 Hz and secure the tubing as much
attach brackets, Model 85444, as possible.

13. On the pH transmitter, read the pH of the process water coming from the
main tank of the process workstation. The pH of the process water should be
between 6.5 and 7.5. If not, neutralize the process water as described at the
end of Ex. 1-1 before proceeding further.

14. Once the process water is neutral, stop the process workstation pump.

15. Open HV5 to drain water from the main hose.

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Ex. 2-1 – Continuous Process Control  Procedure

16. Once the water drained from the hose, close HV5 and disconnect the main
hose from the pH probe flow chamber. Connect this hose to the filling input
coupling of the upper tank as described in the Familiarization with the
Training System manual.

17. Start the pump and slowly fill the upper tank.

18. Once the upper tank is filled, stop the pump and open HV5 to drain the main
hose. Close HV5 and reconnect the hose to the pH probe flow chamber.

19. Start the pump and set the drive speed to 30 Hz.

20. Fill the column up to 12 cm (5 in) of water, then close HV1 and open HV6 to
put the process workstation into recirculation mode.

21. Continuous processes, such as the one proposed in this exercise, are slow
processes. To speed things up, decrease the pH of the process water close
the desired set point, which is 40% (i.e., pH=5.6). Use the metering pump
connected to the acid tank to inject acid solution in the process water. Do not
to go below the set point! Stop injecting acid when the pH is at 42% or 41%.

22. Once the pH of the process water is approximately 40%, use the metering
pump connected to the upper tank to inject fresh water into the column. Set
the metering pump to 100% of its maximum delivery rate.

23. Almost simultaneously, start the draining metering pump at 100% of its
maximum speed.

24. If both metering pumps operate at the same speed, the water level in the
column should be relatively stable. If there is a speed difference between the
two pumps, reduce the pumping speed of the fastest pump until the level in
the column is stable.

Tuning the controller for continuous pH process control

25. Set the controller to PI mode and configure it with the parameters shown in
Table 2-3. Be sure to convert these parameters for your controller. Some
controllers use proportional band instead of the controller gain or reset rate
instead of integral time (or reset time).

Table 2-3. Controller parameters.

Parameter Value
Controller gain (‫ܭ‬௖ ) 1.0
Integral time (ܶ୧ ) 48 s (0.8 min)
Set point 40%

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Ex. 2-1 – Continuous Process Control  Procedure

a The parameters in Table 2-3 are starting values, you may have to fine tune
your controller to refine the control of your loop.

Controlling a continuous pH process

26. Set your controller to automatic mode.

27. Observe the changes in the process variable on the recorder and wait for the
pH to stabilize around the set point. This could take more than 20 minutes.

28. The pH should stay relatively close to the set point (i.e., within 1% of the set
point). If not, refine the parameters of your controller.

29. Once the pH is stable around the set point, set the metering pump connected
to the upper tank to 50% of its maximum delivery rate.

30. Almost simultaneously, set the draining metering pump to 50% of its
maximum speed.

a When setting the metering pumps speed, take into account any adjustments
you have made to stabilize the level and, if necessary, adjust the level again
to 12 cm (5 in).

31. Observe the changes in the process variable on the recorder and wait for the
pH to stabilize around the set point.

32. If the controller is properly tuned, the pH value of the process water should
stabilize within 45 minutes. If the pH does not stabilize, fine tune the
controller again.

The ideal tuning parameters can vary from one setup to another depending
on the type of water used, the delivery flow rate of the metering pumps, the
temperature, the quantity of water in the column, etc. Therefore, be patient
and systematic while tuning your controller.

Neutralizing the process water

33. The process water in both the column and the main tank of the process
workstation contains an acid solution now. Therefore, it is very important that
you neutralize the process water in both the column and the main tank.

34. First, open HV4 to drain the water from the column and the upper tank into
the main tank.

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Ex. 2-1 – Continuous Process Control  Conclusion

35. While the water is draining, open HV1 and close HV6 to stop the recirculation
mode. This makes the water in the main tank circulate into the whole setup.

36. Wait for the water to mix and the pH reading to stabilize.

37. If the pH of the process water is not between between 6.5 and 7.5, the
process water needs to be neutralized.

38. Since only phosphoric acid solution has been added, the process water
should be acidic. Connect a chemical tank containing a solution of 0.08 mol/L
of sodium hydroxide to one of the metering pumps and start slowly injecting
alkaline solution into the process water.

39. Be careful not to inject too much alkaline solution. When the pH is
approximately 6.5, stop the metering pump and wait about 3 minute to be
sure the process water is mixed correctly.

40. If after 3 minute the pH is between 6.5 and 7.5, it is safe to stop the process
workstation pump.

41. If the pH is not between 6.5 and 7.5, inject more acid or base into the
process water until the pH is within the desired range.

Curve analysis

42. Follow the procedure in the Familiarization with the Training System manual
to transfer the data from the paperless recorder to a computer.

43. Stop the system, turn off the power, and store the equipment. Do not forget
to rinse the pH probe and store it into a storage solution as described in the
Familiarization with the Training System manual.

44. Plot the data using spreadsheet software.

CONCLUSION In this exercise, you learned how to control a continuous pH process.

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Ex. 2-1 – Continuous Process Control  Review Questions

REVIEW QUESTIONS 1. What is a dynamical system?

2. What is the difference between an open loop and a closed loop?

3. Name the three main operations in a process control system

4. When studying dynamical systems, which approach is considered more

advantageous? Why?

5. From the point of view of the controller, what is the manipulated variable?

100 © Festo Didactic 86014-00